SKY STAGE ULTRA

BOILER PLATFORM

USER MANUAL

www.skyclimber.com
Sky Climber LLC
1800 Pittsburgh Drive
Delaware, OH 43015
Tel +740 203 3900
Fax +740 203 3901
[email protected]

Sky Stage Ultra Boiler Platform

User Manual

N.V. Sky Climber Europe S.A.

K.M.O. Zone Itterbeek
Nijverheids Straat 23,
Duffel B 2570 Belgium
Tel +32 (0)3 887 81 20
Fax +32 (0)3 887 09 94
[email protected]

UM-36-BOILER.00A 1
October,
2007

FOREWORD
Welcome to Sky Climber.
Congratulations on your new Sky Climber product. All Sky Climber products are
designed and certified to the highest worldwide industry standards. Our continuous
quality control ensures this product is manufactured to the relevant codes.
Nonetheless, all of this work and effort can be and is nullified by improper use.
It is vitally important that you and each and every person who is to utilize the Sky
Climber product, take the time to learn the proper and safe methods relating to
utilization of the Sky Climber product. Safety begins with a familiarization with the
functions and limitations of the Sky Climber equipment. It is your responsibility to
READ AND UNDERSTAND the contents of this manual. If you have any questions
whatsoever, contact your dealer or Sky Climber customer service. It is our desire and
intention to provide answers to your question regarding the proper use of Sky
Climber products. Sky Climber cannot and will not under any circumstances be
responsible in any way for injuries or damage sustained as a result of misuse or
misapplication of the product. Please consult your sales materials to determine other
applicable limitations of liability.
Sky Climber user manual will guide you through installation and operation
procedures.
Sky Climber reserves the right to continually improve its products. Every effort has
been made to make this manual as accurate as possible at the time of publication;
however, there may be product changes which are not detailed in the manual. Please
contact your dealer or Sky Climber customer service on a regular basis to obtain
follow up information and materials.
We remind you to always wear personal fall protection equipment and to make sure
that all persons utilizing the product are fully familiar with its features, including safety
features and limitations, such as weight limitations.

Sky Climber, 2006

All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of the
publisher.
2

CONTENTS SKY STAGE ULTRA BOILER PLATFORM

FOREWORD

CONTENTS

SAFETY GUIDELINES............................................................................................................

OPERATOR SAFETY..

OPERATION SAFETY

SAFETY GUIDELINES -SPECIAL CONDITIONS INSTRUCTIONS:

WINDSPEEDS................................................................................................................

HIGH VOLTAGE.............................................................................................................

WELDING........................................................................................................................

MARINE ENVIRONMENTS.............................................................................................

ASSEMBLY INSTRUCTIONS.........................................................................................

STANDARD PLATFORM COMPONENTS AND PART NUMBERS..............................

STANDARD CONFIGURATIONS & ASSEMBLY LOAD RATINGS..............................

10 & 11

INSPECTION CHECK LIST ..

13

INSTRUCTIONS............................................................................................................

14

Safety Guidelines
Operator Safety
All persons who service, install, dismantle or use suspended access equipment must fully
comprehend and act in accordance with this manual and all appropriate regulations. A
competent person is a designated person, suitably trained, qualified by knowledge and
practical experience to carry out the required task safely.
Training, manuals and other documentation are available at Sky Climber. Do not hesitate
to contact us for more details.
Operators must be emotionally and physically able to withstand the stress of working at
elevations. Do not work at elevations if subject to seizures or loss of physical control.
Operators must be safety conscious, responsible and not under the influence of alcohol,
drugs or other substances.
All persons using suspended access systems must at all times wear safety harnesses
attached by lanyards and rope grabs to independent lifelines. Use short lanyards and
attach the rope grabs as high on the lifeline as practically possible. Lifelines shall be
fastened to a fixed anchorage other than the rigging systems. Do not disconnect or remove
harnesses or lanyards until safely on the ground or until completely disembarked from
suspension system to a safe location.
Safety helmets should be worn at all times when servicing, disassembling or using the
equipment.
Provide protection for operators from collision with overhead obstacles and falling objects.
Provide adequate protection below the suspended system to prevent injury to persons
from falling objects. Keep all persons from beneath suspended platforms.
Maintain contact with your supervisor at all times.
Make a copy of this manual available to every person using, erecting and assembling this
equipment.

Safety Guidelines (continued)

Operation Safety
All suspended access equipment must be handled with care: during handling of equipment,
installation and use (place loads gently on platform).
Inspect and test the equipment before use, rigging, re-rigging, after de-rigging and at
regular intervals to make sure that it is maintained in a safe workable condition. The
supervisor should assign a competent person for inspection purposes. In case of equipment
failures or difficulties noticed during testing and inspection prior to use, contact your nearest
Sky Climber representative and do not use the equipment until it is repaired or replaced.
Only use Sky Climber spare parts. Do not alter any equipment. Maintenance may only be
carried out by Sky Climber representatives.
Verify if all decals and nameplates are properly affixed and legible. If they are obscured or
missing, replacements are available from Sky Climber.
Always verify if a platform is properly counterweighted: check the rigging systems prior to
each shift.
Never load the platform above the indicated safe working load.
In case of an emergency during operation press the red emergency stop button on the hoist
or control unit. The platform will halt immediately (power is cut off, brakes are activated).
Solve the problem first, prior to further use.
Do not use hoists in conjunction with cableless control systems.
Never use suspended access systems for transportation of passengers from one level to
another.
Keep the vertical travel zone of the platform free of obstructions. When running into an
obstruction immediately stop the platform. Inspect the platform and the obstruction for
possible damage and/or hang-up. Proceed in a safe direction. Take care not to overload the
system or get in slack rope situations when running into an obstacle.
Beware of obstacles when there is too small of a clearance between platform and faade.
Use long-handled tools when working at large distances between platform and faade.

Safety Guidelines
Operation Safety (continued)
Do not handle suspended loads in conjunction with suspended platforms.
When leaving a suspended platform (in mid-air) first secure the platform to the face of
the structure in order to keep it from moving away. Do not forget to disconnect the
platform from the structure before lifting or raising, otherwise serious injuries and/or
damage can occur.
Hazardous situations occur when it is not possible to lower platform to a safe position,
over water and public roads.
Never alter equipment once the platform is suspended. Keep all equipment out of
reach of unauthorized persons.

Group

Category

Condition

Temp

Application

Inspection

Normal

>0C/32F

Inspections, light
maintenance, window
washing.

Prior to each work shift.

Contaminated

>0C/32F

Prior to each work shift.

Contaminated

>0C/32F

Contaminated

>0C/32F

Abrasive materials; sand grit,

dust, welding.
Caustic materials; corrosive
chemicals
Adhesive materials; cement,
plaster, paint, caulking,
compound

Freezing

0C/32F

All

Prior to each work shift.

Every hour.

Service Every 3 months

Service Every 3 months

Do not use suspended access equipment in severe conditions: extreme environmental

conditions, corrosive environment, strong magnetic fields, explosive atmospheres.
Do not use suspended access equipment when handling loads could lead to dangerous
situations: molten metal, acids/bases, radioactive materials, brittle loads.

Wind Speeds
Use adequate restraints when lifting height exceeds 40m (131) with wind speeds above
50km/h = 14m/s (31mph).
Do not use suspended access equipment when hazards could arise from wind pressure
acting on
loads having a surface area in excess of 2m (21.5 SQFT).
With the occurrence of high winds the platform should either be lowered to the ground or
raised to the roof top and secured.
Do not use suspended access equipment when wind speed exceeds 50km/hour

High Voltage Power-lines

Refer to regulations, federal, state and local codes when working in the vicinity of
electrical overhead power-lines. Consult the local power company for safe operating
procedures.
The minimum separation between live power lines and platform is 3m (10).
Touching live power-lines may result in death or serious injury.

Welding

During welding, the electrocution hazard and the risk of the welding current passing through
the steel wire ropes shall be eliminated by taking the following precautions:
Use insulated thimbles at each suspension point. Insulate surplus steel wire rope stored
on roof to prevent grounding or, terminate steel wire rope at insulated thimble.
Cover steel wire rope above hoist and Sky Lock for a distance of 1.2m (4) with
insulating material: rubber hose taped in place. Insulate tail line below hoist: extend
downward sufficiently to prevent contact with platform. The portion of tail line hanging free
below platform must be guided and/or retained so that it does not become grounded.
Cover each hoist, Sky Lock and wire winder with protective covers made out of insulating
material.
Connect a ground conductor from platform to work piece. The size of this conductor shall
be equal to or greater than the size of the stinger lead. It must be a secondary conductor
and shall not be in series with the primary conductor between welder and work piece.

Marine Environment
Salty environments may deteriorate aluminum & steel components. Frequently inspect
equipment.
Excess material accumulation Make sure that excess material does not clutter up the
hoist, Sky Lock or platform.

Assembly Instructions
Sky Stage Ultra Boiler Platform
Sky Stage Ultra Boiler Platform is a modular work platform. All components are
welded out of high quality aluminum. The platform length can vary between 1 and 9
meters configurations. A section consists of 2 side panels, a floor panel and 2 top
rails. A rigid structure is formed by attaching sections to connecting frames with
connecting pins. Top rails are telescopic on both sides of the stage. Wall rollers and
casters are optional.

Assembly Instructions (continued)

Step 1. .Assemble platform by placing 2-side panels vertically facing each other; secure in
a connecting frame/post with locking pin to each side panel. Repeat this step for one to
three sections, placing connecting frames, pins and posts in between each section.
Step 2. Place the standard end stirrup at opposite ends of the platform. Use the
connecting frame to attached the stirrup to the platform with pins.
Step 3. Place the folding floor between the two side panels.
Step 4. Place the wall roller on the side panel, one each toward opposite ends.
Step 5. Place the top rails in the posts with pins.
Step 6. Reverse the assembly instructions for disassemble of the platform.
See specific Hoist Operators Manual for instructions on mounting hoist and sky lock to
the platform stirrups.
Repositioning platform
1. Remove all load from the platform.
2. De-reeve hoists.
3. Reposition platform underneath new position of rigging

361019 3m side panel boiler

361023 2m side panel boiler
361027 1m side panel boiler

361010 3m top rail boiler

361022 2m top rail boiler
361026 1m top rail boiler

361021 3m folding floor boiler

361025 2m folding floor boiler
361026 1m folding floor boiler

360111 wall roller assembly

360019 safety pin assembly

361911 end stirrup assembly boiler

361014 telescoping post boiler

361051 end gate boiler

361030 low profile walk by

stirrup
361054 low profile 2nd leg
(required for work cage)

361015 connecting frame boiler

Standard
Configurations
& Assembly
Load Ratings

End Gate

Low Profile Moveable Stirrup

Top Rail

Side Panel

Floor

Connecting Frame
End Stirrup
361019
361023
361027

3m side panel boiler

2m side panel boiler
1m side panel boiler

361010
361022
361026

3m top rail boiler

2m top rail boiler
1m top rail boiler

361021
361025
361026

3m folding floor boiler

2m folding floor boiler
1m folding floor boiler

361014

telescoping post
(not pictured)
connecting frame

361911
361030
361054

end stirrup assembly boiler

361051
end gate boiler
low profile moveable stirrup
low profile moveable stirrup - 2nd leg (required on all SSU work cages)

361015

10

2m
69

16

3m
99

4m
136

30

5m
166

30

6m
196

7m
233

8m
263

9m
293

2
2

4
4

3
4

6
8

3m

1m 2m 3m

1
2

2
1

0*

2
1

560 kg
1250 lbs.

0*

560 kg
1250 lbs.

0*

560 kg
1250 lbs.

0*

560 kg
1250 lbs.

0*

560 kg
1250 lbs.

30
44

560 kg
1250 lbs.

0*

0*

450 kg
1000 lbs.

0*

450 kg
1000 lbs

0*

450 kg
1000 lbs

2
2

44
6

44

Load Rating

1m 2m

Wall Roller Assembly

3m

Caster Assembly

2m

Top Rail

16

Floor Panel

Side Panel

Connecting Pin Assembly

Telescopic Post

Connecting Frame

Locking Clip (part of end stirrup)

Rod (part of end stirrup)

End Stirrup

Platform Length
1m
39

1m

11

Safe Working Load

1. Determine working load limit (WLL) of hoist.
2. Add WLLs of hoists used.
3. Compare total WLL of hoists less the self weight of platform with load rating (LR) of
platform.
4. Use lowest value as the Safe Working Load (SWL).
Do not concentrate all loads but equally distribute over total length of platform.
If loads are concentrated on one half of a platform then the SWL equals the WLL of 1
hoist less half the self-weight of the platform (never exceed floor rating).
The load on the floor panels must not exceed the floor rating: maximum 180kg per
meter platform or 120lbs per foot platform.

12

Check Lists
Inspect prior to installation

Operating instructions are kept with stage at all times

Reject & replace parts when the following failures are noticed:

Cracked or torn welds.

Cracked or torn material.

Deformations that could endanger the structural strength.

Deformations that would not allow normal installation.

Deformed or cracked connecting holes.

Damaged, missing or illegible decals indicating load ratings, configurations etc.

Check components prior to shipment

Use table Standard configurations & Assembly Parts in this user manual to verify the correct
amount of parts prior to shipment. Ensure all decals and/or nameplates are in place and legible.

Inspection after installation

Inspect the platform assembly after installation and prior to each work shift:

Verify load rating per this manual or decals and verify this load will not be exceeded

Verify if all connections have a Connecting Pin assembly:

Side Panel:
4 Connecting Pin assys
Top Rail:
2 Connecting Pin assys
Telescopic Post:
1 Connecting Pin assys
Verify if each Connecting Pin is secured with a Locking Clip.
Side Panel:
4 Connecting Pin assys
Top Rail:
2 Connecting Pin assys
Telescopic Post:
1 Connecting Pin assys

Verify if each End Stirrup has 2 secured Locking Clips or connecting Rod.

Verify if Wall Roller assemblies are tightened.

Verify if all warning decals and rating labels are in place and legible

Verify if provisions are made to protect workers from falling objects above and below equipment.

Verify if stirrups are in line with the roof supports.

13

Logbook
Instruction to the owner
Owner must keep a logbook which contains the following:
Name of the competent person in charge.
Date and name of operator (s).
Serial number of hoist (s) and secondary device (s).
Number of hours equipment in service.
Specification of wire rope.
Number of hours wire rope in use.
Record of any incident and action taken.
Dates of periodic inspection and record of outcome.
Maintenance and repair records shall be kept in logbook.

14